S

Distribution 5. P r o j . / P r o g . / D e p t . / D i v . :

SDent Nuclear Fuels Proiect

2. To: ( R e c e i v i n g o r g a n i z a t i o n ) I 3. From: ( O r i g i n a t i n g O r g a n i r a t l o n ) I 4. R e l a t e d EDT No.: Mechanical Engineeringi8C454 N/A 6. Design A u t h o r i t y / Design 7. Purchase Order NO. : Agent/Cog.Engr.: . I 1 irIAnn N I A

I v - 8. o r i g i n a t o r Remarks: For approval and release

../ I , 9. Equip./Component NO. :

I O . System/BLdg. /Faci I i ty: N / A

11. Receiver Remarks: 11A. Design B a s e l i n e Document7 [I Yes [ X I N O

4/20/98 15. DATA TRANSMITTED (F) (G) ( H ) ( 1 )

IAI IC1 ID1 Item 181 DOcurnentlDrawing No Rev NO NO NO

Approval Reason Orlgl~ R e c e w Des,g fo, ,latar e , I t 1 Title or Desciiption of Data

Transmitted

CVD

N/A

N / A

12. Major Assm. DYg. NO. :

13. P e r m i t / P e r m i t A p p l i c a t i o n N O . :

14. Required Response Date:

Approval Designaror iFI i . s. n. D 0 1 NIA see WHC CM 3 5 .

1 2 71

Reason for Transmittal IGI Dispos#t#on (HI & ill 1 Approval 4 Review 1 Approved 4 Reviewed nolcomment 2 Rc.loase 6 Post Revlew 2 Approved wlcornrnent 5 Reviewed wlmmrnent 3 Iiiformarion 6 Dist IRecelpt Acknow Required1 3 Disapproved wlcornrnent 6 Receipt acknowledged

80-7400-172-2 (05/96) GEF097

ED-7400-1 72-1 10719 1)

S HNF-2402, Rev. 0

Hanford Spent Nuclear Fuel Cold Vacuum Drying Proof of Performance Test Procedure

Kurt J . McCracken F I uo r Dani e l Northwest, R i ch l and, WA 99352 II S Department o f Energy Contract DE-AC06-96RL13200

EDT/ECN: 606764 UC 510 Or9 Code 8C454 Charge Code LHFAT B&R Code: 39EW704000 To ta l Pages: 8 3 - ~ ~ c ~ , , , , r

Key Words SPENT NUCLEAR FUEL COLD VACUUM ORYING FIRST ARTICLE TECTING TEST PROCEDURE W 441

Abs t rac t : Th i s document prov ides t h e t e s t procedure f o r c o l d t e s t i n g o f t h e f i r s t a r t i c l e s k i d s f o r t h e Cold Vacuum Dry ing ( C V D ) process a t t h e 306E F a c i l i t y . The pr imary o b j e c t i v e o f t h i s t e s t i n g i s t o con f i rm design choices and p rov ide data for t h e i n i t i a l s t a r t - u p parameters f o r t h e proccss. The c u r r e n t scope o f t e s t i n g i n t h i s document i nc ludes dpsicjn v e r i f i c a t i o n . d ry ing c y c l e de te rm ina t ion , equipment performance tr .st . ing ot t.he CVD process and MCO components, heat-up and cool -down c j c l e de te rm ina t ion . and thermal model v a l i d a t i o n .

TRADEMARK DISCLAIMER. Reference here in t o any s p e c i f i c c o m e r c i a l product, process, o r serv ice by t rade name, trademark, manufacturer, or otherwise, does not necessar i l y c o n s t i t u t e or imply i t s endorsement, recornendation, or favor ing by the Un i ted States Government o r any agency thereof or i t s con t rac tors or subcontractors.

P r j n t e d i n the Un i ted States o f America. To ob ta in copies o f t h i s document, Contact: Document Cantroi Serv ices , P.O. Box 950, Mai ls top H6-08, Richland WA 99352, Phone (509) 372-2420; Fax (509) 576-4989.

Release Stamp

d Date

Approved for Public Release A-6400-073 (01197) GEF321

HNF-2402 Rev. 0

HANFORD SPENT NUCLEAR FUEL COLD VACUUM DRYING PROOF OF PERFORMANCE TEST PROCEDURE

Spcnt Nuclear Fucl Project First Article Testing (LHFAT)

Prepared by

Numatec Hanford Corporation P.O. Box 1300

Richland, Washington

b

Kurt J McCrackcn, Engr 1 Spent Nuclear Fuel Fluor Daniel Northwest

and E A Smith, E n g I

Fluor Daniel Northwest with

Technical Contributors

J J lnvin Dcsign Authorit) Cold Vacuum Drying Facilih. Numatec Hanford Company

C R Miska, Process Engineer Cold Vacuum Drying Facihh, Numatec Hanford Company

B C Fryer, Consulting Engineer Thermal Analysis John Marvin Incorporated

R Whitehiirst, Desi&m Authority Cold Vacuum Dwmg Facility, DESH

Tor Duke Engineering Scrvices Hanford

P O Box 1970 Richland WA 99352

Hanford Operations and Enginccring Contractor for thc U S Department of Energy undcr contract DE-AC06-96RL13200

HNF-2402 Rei 0

HANFORD SPENT NUCLEAR FUEL COLD VACUUM DRYING PROOF OF PERFORMANCE TEST PROCEDURE

Spent Nuclear Fuel Projcct First Article Testing (LHFAT)

Prcpared by

Numatec Hanford Corporation P O Box 1300

Rxhland, Washln@on

b l

Kurt J McCrackcn, Engr 1 Spent Nuclear Fucl, Fluor Daniel Northucsi

and E A Smith, Engr I

Fluor Daniel Northwest

Prepared by * - E d K J McCrackcn

Numatcc Hanford Corporation

Approvcd b?

Independcnt Reviea

& / 7 h Date

HNF-2402 Rev 0

INDEPENDENT REVIEW

Document Reviewcd Hanford Suent Nuclear Fucl Cold Vacuum Dniing Proof of Performance Test Procedure

Author K J McCracbcn Report No HNF-2402 EDT No 606764

The sublcct document has becn reviewed by the undersigned The reviewer reviewed and verified the following items as applicable [HNF-PRO-445]

* Lnginccring Specification - Design Input - Basic Assumption ApproacWDcsign Methodology

* lielatcd Information - ConclusiodResult Interpretation

HNF-2402 RCV 0

TABLE OF CONTENTS

I O INTRODUCTION 1 I PURPOSE I 2 SCOPE

2.0 REFERENCES AND APPLICABLE DOCUMENTS

3 0 DEFlNlTlONSiACRONYMN LIST

4 0 YAFFTY 4 I GENERAL SAFETY CONSIDERATIONS 4 2 PERSONNEL PRECAUTIONS

4 2 I Iiijuq Notification 4 2 2 4 2 3 4 2 4 LLfting 4 2 5

4 3 I Encrgil-ing Equipmcnt 4 1 2

Job HaIard Analqsis Lock and Tag

Test Equipment Operation 4 3 EQUIPMENT PRECAUTIONS

Equipmcnl Operating Manuals

5 0 ORGANlZATlON RESPONSIBILITIES AUTHORITY, AND ADMINISTRATION S I

5 2

5 3

ORGANIZATION RESPONSIBILITIES 5 1 1 SNF and SNF CVD Projccl 5 1 2 Eiiginecring De~eloprncnt Laborator) (EDL)

I 1 Enginccring Analvsis 1 4 Qualitx Assurance

2 I 2 2 Test Dircctor

2 4 EDL Manager 2 5 Test Engineer 2 h Tcst PcrrormersiOpcralors 2 7 Test Rmieu Board

AUTHORITY Projcct Dcsign Managcment and Design Authority

5 2 i Technical Engineer

ADMINISTRATION 5 3 I Tagouls 5 1 2 Tcst Changcs 5 1 1 Acceptancc Critcria 5 3 4 Test Validity 5 3 i TcstLog 5 3 6 Evccplions 5 3 7 5 '3 X hgnaturcs 5 3 0 Rcpcat Tesling 5 1 I O Tcst Configuration Control

Ewccplion Dispositioning and Closing

6 0 GENERAL INSTRUCTIONS 6 1 INSTRUCTIONS

6 I I Evccptions

2

4

6 6 6 6 6 6 6 7 7 7 7

7 7 7 X 8 8 8 8 8 9 9 9 9 9 9 9

10 10 10 10 I I 11 11 11 11

12 12 12

6 1 2 Test Pcrformanccs 6 I 1 Signoffs 6 1 4 Prc-job Bricfing 6 1 5 Tcst Log 6 1 6 Measuremcnt accurac\

7 0 PREREQUISITES 7 I INSTRUMENTATION CALIBRATION 7 2 ADDITIONAL INSTRUMENTATION CALIBRATIONS 7 3 NDF LEAK TEST 7 4 PRE-JOB SAFETY BRIEFING

8 0 TEST APPARATUS SET-UPS AND PRE-TEST PERFORMANCES X I APPARATUS SET-UPS INSTRUCTIONS

X I I Prerequisitcs X I 2 X I 3 8 1 4 8 1 5

8 2 I X 2 2 Prcrequisitcs 8 2 7 X 2 4 X 2 5 X 2 6 X 2 7 X 2 X X 2 9

Moch Fucl Fabrication Equipment Performance Testing Apparatus (First Arlicle Test Bed) Water Retention Apparatus Vahc FlushingiMCO Water Ingress Test Stand

Fuel BaskctiFucl Watcr Rctcntion Tcsl

Watcr Rctcntion Testing Instructions Bulk Wakr Rcmoval and Totaliration (MCO Only) Process Conncclor Flushing, 5)stem Flushing Erliclencv Hood Vcntilation Test Seal Ring Pcrformancc Tcsling First Articlc Tcsting Apparatus MCS Compulcr Control Sclup and Tcsling

X 2 PRE-TEST PARAMETER ESTABLISHMENT

9 0 FIRST ARTICLE TESTING PRIMARY MANUAL SEQUENCES OF OPERATION 0 I

9 2

9 3

0 1 I Bulk Watcr Drain Scquencc 0 1 2 Bulk Watcr DI Rinse (PWC Llne Flush) 9 I 3 Tcmpered Watcr Hcatup 0 1 4 Hcliuni Purgc or Rcpressuruc Cqcle (Diptube Inlct) 9 1 i Vacuum Drying with Condcnscr 0 I 6 Vacuum Drying without Condcnser 0 I 7 Normal Vacuum Drying Cqclc (8-4-4 Scqnencing) 9 I X Proof Drcing Modc 9 1 0 MCO Cooling 9 1 I I MCO Vcnting 9 1 12 Condenscr Tank Drain Instructions BASELINE ESTABLISHMENT 0 2 1 Prerequisilcs 0 2 2 9 2 3 0 2 4

9 1 I Prcrcquisilcs 9 3 2 9 3 3

Vacuum Baselinc Establishmcnl Instructions Hcliuni Purgc Bascline Establishment Hclium R c ~ ~ c l e Baseline Establishment

30OE, [JPSET CONDITIONS TESTS

LOEP uithoul Loss of Computer Instructions Loss of Computer Instructions

HNF-2402 Rev 0

12 12 12 13 13

13 13 13 14 14

14 14 15 15 15 16 16 16 16 16 17 17 17 21 22 22 23

23 24 24 25 25 26 26 26 27 30

32 32 33 33 13 14 34 34 34 35 35

30

9 3 4 Loss or Slstem Vacuum (Non-Vacuum Pump Failure) Instructions 0 3 i Hcater Upset Shutdown THIRTY-TWO LITER RESIDUAL WATER DRYING TEST 9 4 I Vacuum Pump Only Drying Instructions 9 4 2 Normal Operation Drying Inslructions BULK WATER REMOVAL AND TOTALIZATION 9 5 I Prcrcquisites 9 5 2 0 i 7 FUEL DRYING 0 6 I 9 6 2 0 6 3 9 6 4 0 6 i 9 6 6 0 6 7 0 G 8 0 6 0 9 6 I O Mixed Fucl (Nominal) Normal Drying Reviscd Sequence (Full 8-4-4 Cycle) CASK PURGING 9 7 I Prcrequisitcs 9 7 2 Instructions SPECIAL TOOLS AND SPECIAL FUNCTIONS 0 X I Special Tools 0 X 2 Spccial Functions SAFETY CLASS ISOLATABLE MAIN LINE BREAK 0 0 I Prcrcquisitcs 9 9 2 HEPA Filtcr Port Main Linc Break Instructions 0 9 3 Diptubc Port Main Line Break Instructions SAFtTY CLASS NON-ISOLATABLE MAIN LINE BREAK 9 IO I Prcrcquisitcs 9 I O 2 HEPA Filtcr Port Main Line Brcak Instructions 9 I O ’3 Diptubc Port Main Linc Break Instructions SLUDGE DRYING 9 I I I Prcrcquisitcs 9 1 I 2 Instructions

Bulk Watcr Rcmobal nith Clcan and Empty MCO at Ambient Tempcrature Clcan MCO with Basket and Mock Fuel (all configurations)

Hcat Up Cycle Dctcrmination Pristine Fucl Normal Drying Scqucnce (Full 8-4-4 Cycle) Damaged Fuel Drying Sequencc (Full 8-4-4 Cycle) Mixcd Fucl (Nommal) Normal Drying Sequcncc (Full 8-4-4 Cyclc) Mixcd Fuel (Nominal) CondenserlPurge 1 SCFM Cqclc Dwmg Mixcd Fucl(35 ’C Bath) 8-4-4 CScle Drying Mixed Fucl Vacuum Only \\ith Purgc 1 6 SCFM Cyclc Drying Mixed Fucl ( I 0 “C Condcnscr) 8-4-4 Cyclc Drying Mixcd Fucl Helium Rccycle or Purgc Only Doing

HNF-2402 Rev 0

APPENDIX A

APPENDIX B EQUIPMENT DESCRIPTIONS

APPENDIX C

APPENDIX D CHANGED PAGES

APPENDIX E

APPENDIX F INSTRUMENT CALIBRATION RECORDS

APPENDIX G PRE-JOB BRIEFNG RECORDS

rENTATlVE CVD PROOF OF PERFORMANCE TESTING SCHEDULE

TEST PROCEDURE EXCEPTION INSTRUCTIONS

WATER RETENTION TANK LEVEL DIFFERENTIAL AND VOLUME

35 35 36 36 36 37 37 37 38 39 39 40 40 41 42 43 44 44 45 46 47 47 47 47 47 48 48 48 48 49 49 49 50 50 50 51 5 1

A- 1

B- 1

c- 1 D- I

E- 1

F- 1

G- 1

vi

APPENDIX H

APPENDIX I

APPENDIX J

SIGNATURE VERIFICATION DATA SHEET

LEAK TEST PROCEDURES AND TEST REPORTS

FIGURES

HNF-2402 Re\ 0

H- 1

I- 1

J- 1

V I 1

HNF-2402 Rev 0

LIST OF FIGURES

Figure 1 Water Retcntion Apparatus F i y e 2 MCO Proccss Connector Flushing Effccncy Apparlus Figure 3 CVD Proof of Concept and Sludge Drying Apparatus Sketch Figurc 4 First Articlc Test Bed Layout F i y e 5 Mock Fucl Assembly Figure 6 Mixed Fucl Basket La\out Figure 7 MCO Thcrmocouple Layout Figure 8 Composite System P & ID Figure 0 Rcmote PLC Layout for MCO, PWC, and SCHe Instnuntation F i y e I O SCHc GOV Power and Indication Wirmg Figurc 1 I SCHc and PWC Pressure and Flow Instrumentation Wiring Fibwc 12 MCO Thcrmocouple Wiring F i y c I 3 Proccss Hood. SCHe and PWC Terminalion Panel Layout Figure 14 Test Bed Piping Orthographic (Plan V~ew) Figure I i Test Bed Piping Orthographic (Elevation View)

J-2 3-3 5-4 5-5 5-6 5-7 3-8 J-9

J-10 J-11 5-12 5-13 5-14 J-15 J-16

VI11

HNF-2402 Rev 0

1 .O INTRODUCTION

1.1 PlJRPOSE

The objecti~c of this document is to providc the test procedurcs for thc Cold Vacuum Drying (CVD) Proor of Performance Cold Testing (First Article Testing) in support of the Cold Vacuum Drying subproject (CDVF) Thc CVD Facility and CVD process are described in d e t d in HNF-2356 Spent Nuclear Fuel Project Cold Vacuum Drying Facility OperationsManual The test plan was based on the CVD design as evaluated at thc 90% Design Review (January, 1998), although (to the extent possible) changes identified in thc review are being incorporated during fabrication of test hardware These proof of performance tests will be full scale and T iewed as a continuation of the scale model proof of concept testing performed earlier (HNF-SD-SNF-TRP- 02 I Hanford Spent Nuclear Fucl Cold Vacuum Dqmg Proof of Concept Test Report ) The philosophy has been to procure a ‘first article” of each process system (skid) associated with thc CVD facility However, due to fmdmg and schedulc coustrrunts, only the Vacuum Purge System (VPS) and the Tempered Water System (TWS) \%ill be first arliclc The Process Water Conditioning (PWC) System, MCO/Cask Seal Rmg, Local Process Ventilation Hood qstem pipmg. MCO and cask wll be full scale mockups or prototypes The Safety Class I&C System wi l l not be tested, although a mockup of the Safety Class Helium Injection System will be included in performance testing Somc special tools required for the process such as the process connectors may also be classified as first article Each system identified above will be tested together, as a whole, to validate process parameters sct points and system response to normal and (limited) upset conditions in order to shortcn the “in Tacilit>’ pre-opcrational acceptancc testing phase, and to provide information for the development of the CVD Promss Simulator

1.2 SCOPE

A testing strategy will bc uscd to xalidatc and veri$ that the VPS/TWS process equipment skid can perform its mtcnded function as designed Thc leshng will also verify the performance capabilities of a prototype process ventilation hoodiseal ring assembly, piping, a minimal first generation monitoring and control system (MCS). a portion orthc PWC systcm, and a protolype safety class hehum injection system A transportation cask will bc utilixd with a prototypic MCO including simulated spent nuclear fuel elements Testing will prove the capabilitie5 of the process equipment as a unit

Wherc tcsts indicate shortcomings modifications to the process equipment will be integrated into the dcsign as outlmcd in Lhc VPSiTWS change control work plan (HNF-2548 F m l Article /’race Modification Work Plan) The equipment will be rctested after the changcs are made Modifications will be incoToratcd 1 ia redlimng to the ‘record’ test drawings and documented in a future Design Modification Report AAer preliminan tcsting, the redlined test drawings the Design Modification Report on all process equipment and a future Operation s Maintenance Consideration Report will be forwarded to thc Design Agent lor formal changcs to the proccss cquipment specifications and drawings Revised drawings and specifications will be forwarded to the approprialc vendor as a change ordcr for evaluation and notice lo proceed on the remaining process cquipment Additional details of configuration control are identified later in this document and the VPSiTWS skid change control work plan

T a t arlicles consist of proccss connector MCO internal fillcr basket offset or spidcr’, four Mark IV Eucl basket? and mock pnslnc aid damaged fuel (up to 100% mock damaged fuel elements with open ends andor simulated cracks m four baskcls to provide for maximum walcr retention in the MCO) a Mark IV scrap basket and mock scrap fuel (mock fuel picccs with damaged end caps, mock fuel pieces, 0 25 in to 3 in), fincs ( 0 25 in carbon stccl bcarings or finc gravel), and sludgc simulant (as required) The test articles will bc used to determinc

I

HNF-2402 Rev 0

u ntcr rctention amounts hcating cyclc parameters (set points, ramp rates, and flow rates). bulk \%atcr rcmoval and pipe cleansing parameters, sludgc transport amounts from MCO to treatment system, d n ing duration and end point \erification detection capabilitics, vacuum proccss and drying time establishment, helium rccyclc purge proccss establishment, combination \ acuum and helium recycle proccss drying time establishment, final shipping test performance, caqk purging performancc VI’S skid operation, maintenance and leah chccking proccsses or procedures, cquipment fcaturc testing and gcneral sen icc and safeh class instrumentation, and control system performancc

Thc featurc tcsling \\ill include pcrcormance oC

* * PWC ejector system,

vacuum pumpicondenser helium circulation pump, - svstcmipiping and vahcs. .

proccss conncctor operation, slndgc rctcntion and rinsing techniques,

caak cask hood/seal ring and cask lowcr port connection asscmbly fit-up and opcration, VPS Instrumcntation and gas analysis system and special tool operation

2.0 REFERENCES AND APPLICABLE DOCUMENTS

DOE-RL-92-36. Hanfijrd Site Hoisting and Rigging Manual, Department of Energy, fichland, Washington. 1997

HNF-PRO-07X, LSuhconlrnctor Snfely and Heallh Managemen1 . Rev 1, Fluor Daniel Hanford Company, Richland, Washington. Bell 1997

HNF-PRO-070, Preph .Safity l’lanning, latest revision, Fluor Daniel Hanford Company , Richland, Washington. Bell, 1997

HNF-PRO-OX 1. Lock and Tag l

HNF-2402 Rev 0

Washington. Ruff, I997

HNF-N- 106. ('old Vacuum Drying Proc?f o/ Performance (I+irtt Article) les l ing Log, Fluor Daniel Northwest. Richland Washington, McCracken, I998

HNF-2356. Rev 0, ,Spent Nuclear Fuel P r o p t Cold Vacuum Drying Facility Operation,s Manual, Duke Engineering Services Hanford, Irwin. I998

HNF-2548. Rev 0. 1"zrst Article I'rocess Equipment .SkfdMod$catian Work Plan, Numatec Hanford Corporation. Richland, Washington, Graves. 1998

HNF-SD-SNF-OCD-00 I . ,Spent Nuclear I k l Conditioning I'roducr Criteria, Rev 1, Hanford Corporation. Richland, Washington

HNF-SD-SNF-TP-036, Rev 0, Hanfbrd ,SpenI Nuclear Fuel Cold Vacuum Llrying Proof of I'er/ormance k s t Speci/icalron and Test Plan, Numatec Hanford Corporation, Richland ,Washington, McCrackcii. 1097

HNF-SD-SNF-TRP-02 1; Rev 0, Hanjord Spenl Nuclear Fuel (,'old Vacuum Drying Proof of (bncept 7ksl Reporl. Numatec Hanford Company, hchland, Washington, Ritter, et al , 1997

RDCDESH MCB-SLB-AO6285-CAT-000, MCLS Hardware Canstmclion Accepranc Richland, Washington, DeSemplc, I998

Report 627. filammahility ('haracreristics o/ (bmbustihle Gases and Vapors. Bureau of Mines

WHC-IP-08x2, 3066 /;uciliiy Adminislralion Manual, Rev I , Westing House Hanrord Company, Cronin. I994

W-44 I -P I Rev N. Procuremenl Specification /or the I.abrication, Acceptance 7k.sting. and Shipment o/rhr ( i iM Vrrcuum Drying System /(quipmen/ Process Equipment Sad, Numatec Hanford Compnay, Richland, Washington November, 1997

W-44 1 -P2 Re\ N Procurement Speci/icalion,fiv the Fabrication, Acceptance resling, and Shipment o/'rhc ( b l d Lbcuum Drying I'hcihly Process Water Conditioning Skid, Numatec Hanford Compnay, Richland. Washington November, 1997

W-441 -P4 Kc\ N Procurement .Speci/icalion fiir the Fabrication, Acceptance l'eS17ng, and Shipment of ihe ( b l d Vucuum /)tying I k i h l y Process Hood, Seal I

HNF-2402 Rev 0

3.0 DEFINITIONS/ACRONYMN LIST

BULK or FREE WATER

CLEAN AND DRY

CVD (Cold Vacuum Drying)

DRY

NORMAL SEQUENCE (8-4-4 Cycle)

Water that is easily removed from the MCO or test apparatus by vacuum pumping or system purging with inert gas

Visually clean and d q to the touch

The process of removing water from the MCO and drying ofthe fuel

Dry is essentially less than a 3 torr pressure rise in the system over an hour period Refer to Section 5 3 3 for acceptance criteria

A “Full Cycle. 8-4-4 scquence“ performed during a test is an 8 hour step uith operation of the vacuum pump, condenser and helium purge (at 1 6 scfm), followed b) a 4 hour helium purge at I 6 scfm or recycle (at 10 scfm), followed by 4 hours of vacuum pump operation These durations mal change throughout the course of testing

MCO (Multi-Canister O~erpack) The unit that will hold the fucl assemblies during the interim storage process A hill scale prototype uill be used for the performance tests

MCS (Monitor and Control Svstcm) The MCS is the computer harduarc and software including the programmable logx controllers to monitor and control the CVD process A “first generation” system will be utilized for performance tests

MOCK FUEL

MCO Process Connectors

Unpainted carbon steel tubing that simulates the N Reactor hel, consisting of an m e r and outer fuel element with approximately the same outside and insidc diameter and wall thickness The mock fuel will closclv approximate the surfacc area of the real fuel All the moch fuel elements \\ill be alloucd to rust throughout the tcsting and some elements will be initial11 damaged to providc water retcntion sites and debris as seen on the K Basin fuel and debris

The process conncctors are val\c bodies that allou the MCO and VPS communication, these are to be prototypic for this testing

PWC (Process Water Conditioning) The skid that contains the pumps, elector, storage tanks, piping, valving, and instrumentation required to remove water rrom one full MCO A mock-up w i l l be used for performance testing

RETAINED WATER

SCHe and T I C

Water remaining on articles after bulk water has heen removed

Safety Class Helium and Safetv Class Instrumentation and Controls arc dcfined as Ihc stand alone systcm that is totally redundant and fail safe to prcbcnt hydrogen bum and thermal runaway reactions inside the MCO in thc CVDF lacility These systems wll be a mock up for performance test applications

A

HNF-2402 Rcv 0

The seal ring is the apparatus that is bolted to thc cask top to create a scal between the cask and the MCO to maintain thc tempercd water closed loop system The seal is accomplished b j an inflatable 0-Ring Thc process ventilation hood attaches to the seal ring and provides air flow for remo\mg axborne contaminants (in the CVDF) at the top of the MCO The hood is also used to house the process connectors The seal rmgiprocess ventilation hood assembly will be a prototypc rather than fabricated as a “first article” for these performance tests

The simulation of K Basin fuel sludge The CVD project with information from SNF characterization will provide approximate sludge simulant ingredients and application techniques

Seal Ring/Proccss Vcntilation Hood

SLUDGE SIMULANT

TEST LOGBOOK

TEST PROCEDURE

A logbook for rccording all data and observations by the test performer which are not included in a test procedure

A tcst proccdure determines the steps for each test and provides documentabon for process paranieters that will be cstablishcd during the testing

TWS (Tcmpered Water Systcm) Considercd part of the VPS skid, the TWS contains the pumps, heaters, piping, valvmg, and instrumentation designed to heat the MCO inside thc transporter cask to 8 5 T , or cool it to 10°C Dunng normal operations, the TWS will operatc between 25°C and 50°C

VPS (Vacuum Purgc Systcm)

CVDF CM CSB DAS DOE ECN EDL GOV HNF HRS I & C JHA MCO M&TE MSDS NDE PWC QAiQC RGA SCHc SCIC SNF TWS

The skid that contains thc vacuum pump, helium circulation unit, hcat cxchangers, piping, valvmg, and instrumentation required for the vacuum dqing proccss This skid will be “first article” for pcrformance testing

Cold Vacuum Dqing Facilit) Control Manual Canister Storagc Building Data Acquisition System Department of Encrgq Engiiicering Changc Noticc Engincering Dei clopmcnt Laboraton Gas Operated Vahc Hanford Hchum Recirculation Sqstcm Instrumentation and Control Job HaLard Anahsis Multi Canister Ovcrpack Measurement and Test Equipment Matcrial Safety Data Sheet Non Dcstructi\c Examination Proccss Water Conditioning Qualit\ Assurancc/Qualit> Control Rcsidual Gas Anah /er Safctj Class Hclium Safctl Class Instrumentation and Control Spent Nuclcar Fucl Tcmpcred Water Systcm

5

HNF-2402 Rev 0

VPS WRT

Vacuum Purge System Walcr Retention Tank

4.0 SAFETY

4.1 GENERAL SAFETY CONSIDERATIONS

All mork completed shall be performcd in accordancc with the appropriate Prolcct Hanford Occupational Eafeh and Health Policies and Proccdurcs

A prc-job mccting will bc required bcforc tcsting begins (per HNF-PRO-079) to discuss personncl protccti\c equipment needs (HNF-PRO-083), lock and tag requirements (HNF-PRO-08 I ) , subcontractor SaCctv and Health Managcment (HNF-PRO-07XL and othcr relevant issues

Salctv rc\ iev analvscs or a Hanford Job HaIard Analysis (JHA) checklist and a 306E Specific JHA checklist shall he prepared and appro5ed prior to tcsting in accordance with appropriate Hanford procedures

Thcrc is no radiation work associated with thc test aclnities described in this test proccdure

0111) thc tcst director, cogniiant test cngineer andor their approvcd test pcrsonncl shall operate thc test cquipmcnl

The lollowing scctions spccifj safeh rcquirements and precautions applicable to this tcsting

4.2 PERSONNEL PRECAUTIONS

4.2.1 Injury Notification

Thc 106E building administrator shall be immediately notificd if any pcrsonncl iqury occurs If the injun also uarrants thc need for outside assistance, mcdical aid shall be obtained by phoning 91 1

4.2.2 Job Hazard Analysis

A JHA checklist shall he prepared in accordance with HNF-PRO-079 , Pre-Job Sa/ery Planning, prior to tcsting and approvcd by the industrial safety representative and 306E facility management All personncl pcrforming this test procedure and related work shall read and sign the JHA for this job The on- shift test cnginccr shall be responsible for ensuring this requirement is met

4.2.3 Lock and Tag

Lock and tag shall bc conducted in accordance with HNF-PRO-081, Hazardous Iwergy ('ontrol Program. and /era energy chccks. mechanical or electrical, shall be performed on the affectcd system

4.2.4 Lifting

All inanual lifting shall be performcd in accordance with HNF-PRO-096, Material Handling and

6

HNF-2402 Rev 0

Storage, and all mechanical liits shall be performcd in accordance with DOE-RL-92-36. HanJord Sire Hoi~ling and Rigging Manual

4.2.5 Test Equipment Operation

On13 thc tcst director tcst cnginecrs and test dircctor approicd test perfoxmers shall operate the CVD test equipincnt

4.3 EQUIPMENT PRECAUTIONS

4.3.1 Energizing Equipment

Supplq p o w r to a component must be off when connecting or disconnecting an) electrical cablcs to that coinponcnt Whcre applicable supply power sources shall be lockcd and taggcd m accordance with 4 2 3 to prcvcnt thc unexpccted releasc of haiardous electrical energy

4.3.2 Equipment Operating Manuals

Thc opcrating manuals for thc VPS skid equipment, heaters, vacuum pumps, etc , shall be read, understood (b\ the test performcrs and engineers) and documented on the prcjob briefing forms located in Appendix G prior to testing to prcvcnt equipment damage Personnel safety and equipment precautions specified in thc operating manuals shall be complied with throughout tcsting

5.0 ORGANIZATION RESPONSIBILITIES, AUTHORITY, AND ADMINISTRATION

The Hanford Spent Nuclear Fncl (SNF) Project organi7ation has ultimate rcsponsibilit) for thc CVD pcrformancc tcsts Spccific testing rcsponsibilities arc dcfined in thc following sections

5.1 ORGANIZATION RESPONSIBILITIES

5.1.1 SNF and SNF CVD Project

The Hanford Spent Nuclcar Fuel (SNF) CVD project shall provide the Design Authority, Tcst Director, 7 cchmcal Engineer and Quality Assurance Personnel as rcquired for the CVD proof of performance testing

Thc Hanford Spent Nuclear Fucl Project shall supply a prototypical mechanical closure MCO with shield plug locking ring, and inlcrnal HEPA filter four Mark IV fuel basket prototypes and one Mark IV scrap baskct prototvpc. specifications for mock N Rcactor Mark IV pristene and damaged fuel assemblics and mock w a p fuel In addition the chemical composition, preparation specifications and application procedure for simulated sludge wcrc provided The CVD project will supply the VPSiTWS skids, thc Process Seal k n g Aascmbly mocknp and the proccss connectors, plus a chiller required for thc VPS chilled water systcm (minimum 10,000 Btuh at 0°C) The CVD project also supplied the MCS system and design spccifications for an cquivalent PWC, safct). class hclium purge, and instrumentation systcms (SCHc and SCIC)

7

HN F - 2 4 0 2 Re\ 0

5.1.2 Engineering Development Laboratory (EDL)

Thc proof of concept test stand, test mock-up apparatus (except VPSITWS), and test articles are to be fabricatcd b) thc 106E Building EDL pcrsonncl Tcst laboratory personnel shall prepare mock fuel, sludge simulant, and scrap fucl, to conduct retained water location tests, and to assist in first article testing as required EDL shall modify (as necessary) mock fuel assemblies using commercially available steel EDL also shall construct thc piping interfaces to mechanically connect the skids with design specified piping diamctcrs and cquibalcnt lcngths to provide powcr ror all components and skids EDL shall fabricate the cquivalent SCHe prototype, PWC mockup and process ventilation hood and piping assembly from commerciall) availablc general service components

5.1.3 Engineering Analysis

Support from Engineering Analysis. currcntl) John Marvin Inc and FDNW SNF Engineering assists, as needed. in thc tcst requirements and to perform compilation of testing results and tcst report preparation

5.1.4 Quality Assurance

SNF Project Quality Assurance (QA) shall provide review of the test procedurc(s) and will review the test report SNF Project Quality Control (QC) shall providc support for the dimensional measurement of test components and indcpendent verification of tcst apparatus set-ups and shall provide independent verification of selcctcd hold andor witncss points in thc test procedure SNF project QC shall provide certified personnel to support rncasurements or verification activities rcquired by the test procedure

5.2 AlTHORITY

5.2.1 Project Design Management and Design Authority

Thc CVD prolcct managcmcnt includes proJect management and design authoritics The design authority has final authority over the conduction, repetition, or cancellation of any or all CVD tests The CVD managcment and design authoritv directs the tcst director and may consult the technical cngineer and test director lor tcst input The project management has the responsibility to communicate an) changes to the

First Articlc testing that ma\ impact other SNF organi7ations such as operations and start-up

5.2.2 Test Director

The first articlc testing tcst director is responsible for thc ovcrall performancc or the test proccdurc and personncl safetq The tcst director shall be qualified by familiarity with the project, systems functions, and equipmciit operation The tcst director is also responsible for all tcst material and personnel resource coordination Thc tcst director dirccts the tcst engineer and reports to the design authority and project management The tcst director mav also be a test engineer and a test pcrformer The tcst director can act as both thc test director and test engineer Thc tcst director shall be appointed by the CVD project managcment and is currcntl\ assigned from FDNW In thc event of test director absence, the test dircctor or project managcmcnt may assign thc rcsponsibilitics to another qualified individual

8

HN F - 2 4 0 2 Rev 0

5.2.3 Technical Engineer

Thc tcchmcal cnginccr, currcntly from John Marvin Inc ,will provide test design information and test data reduction as rcquircd during the coursc ofthcsc tests The technical engineer may request a rcpeat test with concurrcncc from the dcsign authority and test director

5.2.4 EDL Manager

The EDL manager is responsible to coordinate all activities in the 306E facility and provides an inlcrfacc with building management and personnel to establish priorities and requirements The EDL manager shall assure the test sct-up, conduction, and salcty precautions are within the facility guidelines outlined in WHC-IP-0882 306P I~acilily Administration Manual

5.2.5 Test Engineer

Thc tcst cnginccr is rcsponsihlc for directing performance of the test procedure and for personnel and plant safch as related to the performance of the test procedure The test engineer directs personnel assigned to the tcst procedure The test engineer reports to and is designated by the test director The test engineer may bc thc test dircctor and a test performer

5.2.6 Tect Performers/Operators

Thc tcst pcrlormcrs arc dirccted by the test engineer The test pcrlormers are directly responsible for test procedure performance, pcrsoilncl safcty, and equipment precautions designated in the equipment operation manuals Thc test performers report to the test engineer and test director Thc test performers are dcsignatcd b\ the test director

5.2.7 Test Review Board

Thc test reticw board shall pro\ide a review of the test procedure(s), design modification report, and final test rcport(s) All redline changes to the first article skids, that arc under configuration control, are SUbJeCt to rc\ icv bv the appropriate members of thc tcst review board as defined in the skid modification work plan Thc tcst rc\iew board consists of project management, design authority, test director quality assurancc, safcty dcsign agcnt, tcst facility management, technical engineer, and DOE for informational purposcs

5.3 ADMINISTRATION

5.3.1 Tagouts

Tagouts shall hc conductcd in accordance with the appropriate Project Hanford Occupational Safety and Health Policics and proccdurcs. and in accordance with the WHC-IP-0882 306E F a ~ i l i ~ Adminiamxion Manual as applicablc Zcro energy checks (mechanical or electrical) shall bc performed on the affcctcd systcm All tagouts shall be applied in accordance with scction 4 2 3

HNF-2402 Rev 0

5.3.2 Test Changes

Tcst proccdurc changes required during testing as described in HNF-SD-SNF-TP-036, cxcluding the skid drawings, sketches, or specifications (see section 5 3 I O below and as descnbed in the skid modification work plan), may be made immediately in the field copy test procedure change sheets, provided that the changcs cannot affect operating test facility safety, function, or performance and will not cornpromise or influence tcst data Any such change must be recorded in the change log as a change exception and in the test log Test parameters may be changed with concurrences of the appropriate members the test rcview board (see scction 5 2 7) At a minimurn, the design authority, test director, EDL manager, and the technical engincer shall concur with all test changes Changes to quality assurance functions (e g , QAiQC verifications inspcctions, documentation) requires concurrence of the SNF Project Quality Engineer All procedure changes shall be incorporated (at the end of testing) with an ECN

Tc5t changcs that affect opcrating facility safety, function, or performance, or will compromise or influence tcst data arc made via cugineering change notice (ECN) to the test proccdurc. the ECN will bc appro\cd b\ (at a minimum) the design authority, test director, facility manager (for facility safetv), EDL manager thc technical cnginecr and the appropriate members of the Tcsl Review Board

T a t s outlined in this plan may be pcrformcd out-of-sequence, if deemed appropriate by the test director with concurrcncc of thc EDL managcr, and thc change documented in the test log

5.3.3 Acceptance Criteria

Thc tests outlined in this document are expected to validate andor establish a ‘ rccipe” for operation ofthe CVD proccss The design input parameters shall be entered to the process control system and observations shall bc madc to determine minimum heat-up cycles and maximum water removal rates For any step in the test procedure that has an associated acceptance criteria, the value will be dcsignated in that step The governing acceptance critcria, based on commercial practices, is an internal ~acuum chamber pressurc rcbound of Icss than 3 torr within 1 hr If the pressure rebounds above this limit, the drying specimens (mock fucl sludge or scrap fucl) arc not completely dry The pressure rebound starts after the bacuum vcscl is pumpcd doun to a base prcssurc, tentatively 0 5 torr, and the vacuum pump is isolated

5.3.4 Test Validity

A spccilic tcst is valid if cquipmcnt, instrumentation, and data acquisition systems function satisfactorily during the test (I e vacuum pump maintains required system vacuum over the tcst duration, temperaturc detectors provide accurate readings, pressure gauges maintain accurate pressure indication. computer maintains data acquisition of these parameters and other control functions, ctc ) Hardware failures must be recorded in an exception log, in a test log, and on an exception page The test cngineer will decide whcthcr to continue with the tcst procedure in the event of a test step or equipment failure The validity o f a test iu which harduarc failurcs occur and the need to repeat it will be determined by the test director and Test Re\ icw Board

5.3.5 Te\t Log

A narrative log of testing activities is to bc maintained by the test engineer Page numbers and dates shall be entcrcd as ncw pages arc added Each added page will bc stamped “CONTROL COPY” Dark, rcproduciblc iilk shall be used for all entries The test log is in HNF-N- 106, Cold Vacuum Drying Proof of 1’erforrnanc.r (P in / Article) lar ing Log

I O

HNF-2402 Rei 0

5.3.6 Exceptions

Thc tcst proccdure shall not be closed with open exceptions All cxceptions shall be recorded per the test procedurc cxccption instructions located in Appendix C unless it is immediately correctable and retested Prior to the close of thc test procedure, each exception is dispositioned When all exceptions are dispositioncd then thc tcst proccdure may be closed The test proccdure does not have to bc changed due to the existence of an cuception, howcvcr a change mav be warranted if the exception causes a significant impact to the performance of thc tcst proccdure

5.3.7 Exception Dispositioning and Closing

Dispositioning of exceptions can be accomplished in one of two ways, clear the cxccption or change thc rcquircmcntiproccdure (refer to Section 5 3 2 and 5 3 6) Exceptions are then closcd when they havc been dispositioncd and sigucd by the test director

5.3.8 Signatures

All pcrsonncl cntcring sibnatures or initials m the test procedurc must print their name and provide their signature and initials in thc tcst procedure sibmature identification log located in Appendix H

5.3.9 Repeat Testing

Onc intcnl o l first articlc tcsting is to berify computer models, ilvcrification is accomplishcd, thcn repeat testing will not bc rcquircd during pcrformancc tcsting However, if invalid results arc obtained because of equipment failure. or unexpected results are obtained, a particular test(s) will bc repeated

If rcpcat tests are required because of confirnation or design changes, additional copies of applicablc proccdurc sections or tcst procedure data sheets may be used The addition of procedure sections to be uscd Tor rcpcat tcsting shall be added as Repeat Testing, noted in Appendix K, and concurrcd with by the test dircctor and EDL manager

5.3.10 Test Configuration Control

Chmges required to thc test procedure, shall be controlled per section 5 3 2 Changes to facility usc hardwarc shall be controlled by HNF-2548, Hanford LSpent Nuclear h e 1 Cold Vacuum I l i ymg Proces, Zquipmenr \bid ModiirJication Work Plan

Identified facilit). use hardvare drawings, sketches, and specifications included as attachments within the test proccdure shall be identificd "Dciclopment Control" Changes, additions, or dcletions to the "Dcvclopmcnt Control" drawing, skctcb or spccification shall be controlled by either marking thc change in "red" or prcparing additional pagcs or skctchcs and identifying traceability with the affected drawing, sketch, or spccification All changcs shall bc sibmcd and datcd next to each change by the design authority (for dcsigii baschnc documents) or cognilant engineer ([or all others) and also noted in the tcst log Thc "Dc\clopmcnt Control" proccss spccified within the test plan and procedure shall be applied to rcquircd changes during this phase of decclopment, fabrication, and tcsting Drawings, sketches or spccification originals under "Dc\clopment Control" shall not he rcvised by ECN At the end of developmcnt and fabrication all "Dc\ clopmcnt Control" changcs shall be incorporated into the appropriate engineering

HNF-2402 Rev 0

documents Enginecring drawings shall be prepared and rclcased as H-series or "SK" drawings in accordance with HNF-PRO-242 (formerly HNF-CM-6-1 EP-I 3)

6.0 GENERAL INSTRUCTIONS

This section provides general requirements that apply during the entire test proccdurc performancc All Tcst Engineers and Tcst Pcrformcrs must read this section prior to performing any test proccdure testing

6.1 INSTRUCTIONS

6.1.1 Exceptions

An cxccption shall bc loggcd for any stcp not meeting the requirements of thc tcst procedure An exccption number must be obtaincd and a short description entered in the exccption log in the Appcndix C

6.1.2 Teqt Performances

Each section IS performed sequentially Each test shall be performed at a minimum of two (2) times for data repeatabilih unless otherwise noted by the test director Thc Tcst Engineer has authority to perform major scctions out orscquence (without a test procedure changc) provided

Thc " Prereauisites" in that section are coinpleted

Performing thc scction on1 ofscqucncc will not adversely impact any unfinishcd (previous or subsequent) sections or advcrsely impact thc test procedure performancc schcdulc

Thc scction docs not bypass basic cquipmcnt control and interlock tests (rclatcd to the section) pcrformed 111 prcvious scctions

Concurrencc from the Technical Engineer and Tcst Dircctor arc obtained and entcrcd into the Test Log

NO HOLD POINTS (Hold Point or HP) shall bc by-passcd

Whcn using computer manual scqucncing (scction 9 I ) , the valves that arc rcfcrenced are to bc actuatcd in thc ordcr in which thcy arc listed Any changes to this ordcr, a test cxception or rcd linc changc shall bc rcquircd and notcd in thc testing log

6.1.3 Signoffs

Thc Test Engineer sign off of test steps certify that direct obscrbation or inspection has bcen made or that a rcport was rcccived from tcst personnel signifying that the stcp was performed

6.1.4 Pre-job Briefing

Prior to thc start of any work performed undcr this tcst procedure, a pre-job brichng will be conductcd Thc mccting shall bc chaircd by the tcst director For each pre-job bricfing, a form will bc filled

12

HNF-2402 Rcv 0

out and placcd in Appendix G At a minimum, thc rollowing topics will be discussed at the meeting

a

h

Expected testing to occur on shirt

Special sarei\ concerns. including lifting precautions and electrical safety,

c

d

General facility and tcst proccdurc status, and

Rei IC\% of thc JHA

6.1.5 Test Log

A tcst logbook will be maintaincd by the Tcst Enginccr Thc Tcst Engineer shall be the desibmated logbook custodian All pertinent observations, off-normal events, sketches, photographs, etc , shall be logged All logged cntrics shall be signed and dated in dark, reproducible ink Additional notes or entrics relating to a procedure data sheet cntly field or information shall be adequately referenccd to the appropriate section of this procedure The test log is HNF-N-106

6.1.6 Measurement accuracy

Dimensional mcasurcments shall be taken to the nearest millimeter Temperature measurements shall be taken to the nearcst2' C and time measurements will be to the nearest second Pressure measurements shall bc tahcn to thc nearest 0 5 psig, psia and 0 1 torr Calibration records shall be retained in Appendix F

7.0 PREREQUISITES

Thc following sections specify prerequisites that must be completed prior to thc start or the entire test proccdurc In addition. some sections of thc test procedure have special prerequisites that must bc completed prior to starting that particular section onl)

7.1 INSTRUMENTATION CALIBRATION

Thc tcst cnginccr and QAiQC rcpresentatiw shall verify that test Instrumentation, items 8 I through 9 I in Appcndix F, arc within their current calibration cycle Place all calibration records in Appendix F and sign below to confirm that test instrumcnlation arc HSL calibrated, field venfied, or have manufacturer calibration shects

Hold Point I Test Engineer Datc

Datc

7.2 ADDITIONAL INSTRUMENTATION CALIBRATIONS

lnstnimcntation residing on the VPSiTWS skid, items 1 through 79 in Appendix F, shall be calibrated by the Hanford Standards Lab (HSL), licld vcrificd by using calibrated M&TE and logged, or have the

13

HNF-2402 Rev 0

manufacturer calibrations sheets as prescribed in Appendix F Record all information on the field verification data sheets located in Appendix F At a minimum, M&TE calibration number, last and next calibration date, as found and as left five point data across the instrument range, and any comments on instrument calibration adjustments

Hold Point I Test Engineer Date

I QC Date

7.3 NDE LEAK TEST

A helium lcak test shall be performed by qualificd NDE personnel on all VPS process lines prior to tcsting Also, a helium leak test shall he performed on the assembled MCO The leak ratc of the process system. which includes the VPS, HRS, and MCO, shall be less than 1 x 10 ‘ std cm’is He If there is excess leakage in the svstcm pcrform diagnostics, and contact test engineer and EDL staff to assist in system repair After repairs are complete, rcchcck lcak ratc

Record equipment calibration information in Appendix F Sign below to indicate initial system lcak tests halt been satisfactorily completed

Hold Point I Test Engineer Date

NDE Date

7.4 PRE-JOB SAFETY BRIEFING

Prior to the start of any work performed under this test procedure, a pre-job safety briefing shall be conducted Additional pre-job briefings will be performed throughout testing as required by the test director The briefing shall bc chaired by the lest dircctor or test designee For each pre-job briefing, a form provided shall be completed and placed in Appendix G At a minimum, the following topics will be discusscd

Expected testing to occur on shift Special safety concerns, including lifting precautions and clcctrical safety General facilitv and test procedure status Rei i e ~ of applicablc MSDS’s Re\ leu of the JHA

Place all prc-lob briefing forms in Appendix G

8.0 TEST APPARATUS SET-UPS AND PRE-TEST PERFORMANCES

8.1 APPARATUS SET-UPS INSTRUCTIONS

This section provides input rcquircd to set-up and fabricate the first article test bed and miscellaneous

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HNF-2402 Rev 0

test stands such as thc mock fuel fabrication. the first article test bed, the watcr retention and totaliration test stand, and the valve flushing test stand

Photographs shall he taken of each test apparatus and test arliclc(s) and placed in the test log

8.1.1 Prerequisites

Thcsc set-ups and verifications ma) be performed concurrently or out-of-sequcncc depending on test schedule. cquipmeiit deliveries, and/or tcst directors discretion, however NO HOLD POINTS (HP) shall be by-passed

8.1.2 Mock Fuel Fabrication

Assure the mock fuel test articles are fabricated in accordance with the test director and QC inspect 10% of thc mock fucl test articles in reference drawing SK-2-300395 Refer to Appendix J Figure 5 for general fabrication assistancc

Siniulated course scrap fucl shall be fabricated by cutting mock fuel elements (inners and outcrs) into random lengths ranging from 114 in to 3 in long Simulated fine scrap fuel shall be fabricated by breaking cast iron pipc, 1 to 3 inches in diameter, into small pieces ranging from 114 in to 1 in shards Note inventory simulated scrap fuel in test log book

Hold Point 1- Test Engineer Datc

I QC Datc

8.1.3 Equipment Performance Testing Apparatus (First Article Test Bed)

Assure the test apparatus is fabricated in accordance with the test plan and the test director Instrumentation calibration records are supplied and located in Appendix F Changes to the test fixtures that differ from the 90% shall be documented in the Test Log Book HNF-N-106 (Refer to Figure 2, 8,9, IO, 11, 12 13 14 and 15 in Appendix J for general set-up assistancc ) Figure 8, (H-1-83770) the CVD proccss system composite P B ID shall he avavilable on a full s i x drawing sheet maintained undcr the development configuration control at thc test facility

Apparatus List

Hood Proccss Piping Assembly PWC & Connection Piping Ventilation Hood and Seal Rmg Cask Water Retcntion Apparatus Electrical Power Distribution

VPS Chilled Water TWS Chilled Water Helium Supply CompressedInstrumcnts Air Supply Water Supply PWC Water Heating System

1- Test Engineer Datc

HNF-2402 Rev 0

8.1.4 Water Retention Apparatus

Assurc the tcst apparatus is fabricatcd in accordance with the test plan, the test director and calibration records for the measuring and test equipment requiring calibration are current and copies in the log book txccptious to thc 90% dcsign packages shall be documented in the Tcst Log Book HNF-N- I06 Refer to Figure I (Appendix J) for general set-up assistance

Test Engineer Dale

8.1.5 Valve Flushing/MCO Water Ingress Test Stand

As\cmblcifabricate test apparatus per test engineer’s direction using Figure 4 (Appendix J) as a guidc Assuring thc isolation valvc is in the vcrtical orientation and proper installation of the instrumentation

1- Tcst Engineer Date

8.2 PRE-TEST PARAMETER ESTABLISHMENT

This section provides first article pre-testing to establish parmaters for mock fuel and basket water retention, bulk water rcmoval and totalization, process connector flushing and MCO water ingress testing, m~tialation hood airflow tcsting, scal ring leak testing, and MCS set-up, control, and data logging testing

8.2.1 Fuel BasketiFuel Water Retention Test

This scrics of tcsts examines the amount and location of water retained on a prototypic, single MCO fuel basket mock fucl in a varictl of conditions ranging from pristine to fully damaged with simulated scrap Thc tcst apparatus is describcd in section 8 2 3 and Figure 1 (Appendix J) The pristine and damaged fuel uatcr rclcntion tcsts \\ere pcrformcd during the proof of concept testing and documented in Ritter, et a1 (1997) Thc tests ~ 1 1 1 bc conductcd with the baskct of mixed mock fuel as shown in Figure 6 (Appendix J), tbcn thc t a t a i l 1 bc rcpcatcd adding scrap fnel with and without fines When each test article I S removed from thc watcr, a closc \ideo camcra inspcction nith editorial commcnts will indicate where the remaining watcr is lomtcd Thc test article shall be monitored during the drain time, up to 30 minutes after removal from water A~eraging techniqucs will be employed for thcsc tests due to the uncertainty in>ohed in qual i fhg and quantifying retained water Equipment rcquired for MCO water retention tests IS

water retention mcasuring dcvicc, prototypic MCO fuel baskct. moch N Rcactor fucl (pristinc and damagcd). simulated scrap. and protohpic MCO scrap basket with fines compartment

8.2.2 Prerequisites

1 0

2 0

START L idco rccording prior to cach test

RECORD data in test log book

HNF-2402 Rei 0

8.2.3 Water Retention Testing Instructions

i n

2 0

3 0

4 0

8.2.4

FILL the WRT with approximatcly 61 cm (24 in ) of water (enough water to completely submerge thc prototypc fuel baskct) ALLOW the water to settle (1-5 mm) and RECORD the initial water le\ el using the lcrnier scalc and hook gauge or other apparatus

SUBMERGE the fuel basket in thc WRT ALLOW basket to soak for 5-10 minutes ELEVATE baskct abolc thc watcr surlacc and ALLOW dripping to start Within 2 minutes RECORD the first watcr lcvcl indication ALLOW watcr to drip for 30 minutes Into the WRT RECORD at a 15 minutc intcnal and thc final WRT lcvcl

DETERMINE thc amount orwatcr Icft on thc basket (initial and final) by using the leicl differential volunic cquitalent graph in Appcndiv E

PLACE baskct in an air strcam for approximatcly 2 hours or until basket is visually dry and &y to thc touch REPEAT steps 1 0 through 3 0 one additional timc for the same basket ALSO REPEAT TWO (2) timcs for basket and fucl assembly configurations (pristine, damaged, mixed), sludge, baskct, fuel, and sludge, scrap basket, and scrap basket and scrap FILL out watcr retention tablc in t a t log book (Note Due to some of the difficulties that may be encountered mcasure sludge and dcbris \+atcr retention, these tests may be NA until a later date or disregarded Thc decisions shall bc notcd in the test log with concurrenccs from thc tcst dircctor, technical engineer, and design authoritv )

Appcndix E complctc 1- Tcst Engineer Datc

Bulk Water Removal and Totalization (MCO Only)

8.2.4.1 Prerequisites

1 0 Fill MCO with approximately 150 gallons of watcr using a technique describcd in section 9 1 10

8.2.4.2 Clean, Dry, and Empty MCO Instructions

1 0 Evaluate thc MCO Bulk Watcr using scction 9 I I

8.2.5 Process Connector Flushing, System Flushing Efficiency, and MCO Water Ingress Test

An apparatus, conceptuallv shown in Fibarc 4 (Appendix J), shall be fabricated to test the VPS dc- ionired water flush after the bulk water draining process The apparatus consists of a process connector and shield plug valve asscmbly prototype and a gas opcratcd ball valve (GOV) down stream of the process conncctor This GOV \\ill utilirc the same seats and seals as specified in the 90"A~ Cold Vacuum Dlying Svstcm Equipment Process Equipment Skid, W-44 1 -P 1 Revision N procurement specification for GOV 1230 and GOV I201 Thc purpose ofthis test is three rold to identify any sludge traps in thc process connector, to optimirc flow scttiiigs providing maximum sludgc clcan-out without introducing addcd water back into thc MCO and to tcst thc scaling and isolation capabilitics of the valve after thc introduction of sludgc

Thcsc tcsts \\ i l l dctcrminc i1'sludge will remain in thc process connector, piping, and valves after

17

HNF-2402 Rev 0

rinsing If so, significant connector redesign and valve scat specification ma) be necessab to reduce an) radioactiw dose an employee may receive while handling the connector The process conncctor sludge retention tcst is conducted using a process connector and flowing a Magnafludsludge simulant/water solution through thc connector and test bod) The process connector will be removed from the test body and visually inspected with ultra-violet light to qualitatively determine the amount of sludge simulant on the process connect The process connector mill then be replaced on the test body and a flushing routine will be initiated Once again, the process connector will be removed from the test body and visually inspected with UV light to determine the amount of sludge simulant remaining in the connector If the connector shows signs ofbuild- up , the proccss connector should be redesigned and retested to minimi7e sludge build-up The process connector will also be leak checked after 20 donningidoffing and actuating sequences to check for any O-ring and seal le,ikagc

Thc MCO drain process is controlled primarily by the VPS 1230 valve for isolation This vahe has the potential lor scat and seal scarring from the MCO sludgc being trapped prior to rinsing The component must remain suitable lor its intended use A sludge simulantlwater mixture shall be flowed through the vahe and rinsed This process ma) bc repeated any number of times and valve leak tightness re-verified

8.2.5.1 Prerequisites

I .0

2 0

3 0

4 0

Test stand has been fabricated per section 8 I 5

MIX sludge pcr test engineer’s direction using uater, Kaolin, and/or Minusil vith a Magnaflux as a traLcr additn e Notc Mixture ‘recipe” in logbook

Sludge Preparation I Test Enginccr Date

RECORD all data in the test log book

NDE leak check process connector to bc leak tight to I 0 x IO ‘ std cclsec He

Test Engineer Date

I NDE Date

8.2.5.2 Apparatus Set-up and MCO Water Ingress

8.2.5.2.1 Acceptance Criteria

Air flow and/or water flon DOES NOT enter the drop out tank for a period of30 minutes

8.2.5.2.2 Instructions

1 0 ATTACH the process connector with bottom 0-Rmg in place to the mounting apparatus TORQUE the process connector to 40 ft Ibs using a criss-cross pattern in asending torque stages and a final chcck around the bolts (Note use unlubed condition, per HNF-N-62 Multr-Canicter Overpack

18

HNF-2402 Rev 0

(bmponenl /etring, Vol I . Ruff, 1997)

OPEN proccss valve to internal process connector stop

SET and ADJUST as necessary, the air pressure to 20 psig and flow to 5 scfm cjector flow pump and ALLOW flow to stabilize rcadings SET and ADJUST as necessary. the DI water pressure to 20 psig and flow to 5 gpm

FLUSH process connector for 5 minutes and OBSERVE and RECORD any watcr drop out in the drop out tanh on the bottom ofthc mounting apparatus IF ANY water is observed, INCREASE AND/OR DECREASE thc air flow and/or water flow until water DOES NOT enter the drop out tank for a period of 30 minutes RECORD thc final prcssurc and flow settings in tbc data table

START the RECORD ejector inlet flow and pressure

2.0

3.0

4.0

5 0 ISOLATE DI watcr and air sourccs THEN STOP the ejector flow pump, and THEN close thc isolation vahc to the ejector NOTE: This sequence must he followed to assure thc system stays as dn, as possiblc

8.2.5.3 Process Connector Flushing Efficiency Test

1 0

2 0

3 0

4 0

5 0

6 0

7 0

X 0

REMOVE process connector from apparatus RECORD the process connector TARE weight (+ 1 gram) APPLY an eben coating of sludge mixture approximately 1/16 in (1 6mm) thick to the process coiincctor cakity CAUTION: DO NOT apply sludgc to thc 0 - h n g seal on the process conncctor bottom IF thc O-ring becomes contaminated with sludge--REMOVE using a damp cloth VIDEO TAPE thc sludge Iaycr undcr an ultraviolet lamp to verify the Magna-flux traccrs

REMOVE thc process \ a h c simulator from thc mounting apparatus RECORD the process \alvc TARE weight (+ 1 gram) APPLY an cvcn coating of sludgc mixlurc approximately 1/16 in ( I bmm) thich to the proccss valvc cavity and top interface scaling surface IF the threads bccomc contaminated with sludge-REMOVE using a damp cloth VIDEO TAPE the sludgc laycr under an ultra\iolct lamp to wxif\g thc Magna-flux tracers

RECORD thc processor connector and proccss valve INTERMEDIATE weight

INSTALL thc proccss baht to its open position in the mounting apparatus INSTALL and TORQUE process conncct to 40 ft Ibs using a criss-cross pattern in asending torque stages and a final check around the bolts (Note Use unlubed condition per HNF-N-62Mul/r-('ani\rer Ovi rpad ( omponent /e\ting, Vol I Ruff 1997) on the mounting apparatus

START thc cjcctor f lon pump and ALLOW flow to stabihrc the isolation \alve to the cjcctor OPEN thc DI water isolation ialve

FLUSH thc systcm for 5 minutes OBSERVE proccss conncctor cxtcrior for indications of watcr bcing forccd passed the am 0-Ring seals

OPEN air isolation valw OPEN

ISOLATE DI watcr and air sourccs THEN STOP the ejector flow pump, and THEN close the isolation I ah c to thc cjcctor NOTE: This scquence must bc followed to assurc the system stays as drq as possiblc

REMOVE proccss conncctor and VIDEO TAPE inspection with an ultraviolet lamp to identif) any remaining sludge traps in the proccss connector RECORD observations in logbook REMOVE

HN F - 2 4 0 2 Rev 0

process connector and VIDEO TAPE inspection with an ultraviolet lamp to identify any remaining sludge traps in the process conncctor RECORD obscrvations in logbook

9 0 RECORD the process connector and proccss valvc FINAL wcight

I 0 0 IF MagnaFluv is obsen cd in arcas of the process connector and process valve internals

I 1 0 REPEAT steps 3 through 10 but incrcasc thc flush lime 5 minutes on each repeat tcst and RECORD observations and times in logbook until the connector is flushed clean with no visible indications of the MagnaFlux traccr

CLEAN the process connector, RE-APPLY sludge as described in steps 1 and 2 and REPEAT steps ? through IO at the flush time determined in stcp 1 1 0 REPEAT at test director discretion

12 0

13 0 INSPECT proccss connector 0-Rmgs under a bench top microscopc for abrasion damaged and RECORD observations in test log

I 4 0 NDE lcah chcch process connector to be leak tight to 1 0 x 10.‘’ std cclsec He

I Test Engineer Date

NDE Date

8.2.5.4 Valve Sealing Test

1 0

2 0

3 0

4 0

5 0

NDE COMPLETE a lcah chcck oCthc ejector isolation valve to 1 x 10 cm’ls He PLACE leak chcck rcport in the log book and SUMMARIZE results in Appendix I

I NDE Date

1- Test Engineer Date

MIX a liquid sludge per tcst engincer’s dircction using water, Kaolin. and/or Minusil with a Magnafluv as a traccr additive Note Mixture “recipe” in logbook and VIDEO TAPE consistency

Sludgc Preparation Test Engineer Date

REMOVE thc drop out tank from the mounting apparatus and REPLACE with tubing into the container with liquid sludge

START the elector flow pump and ALLOW flom to stabiliz OPEN the isolation >alve to the CJeCtOr

During the rcmoval or the sludge, ACTUATE the ejector isolation >alve 5 to 10 times

20

HNF-2402 Rev 0

6 0 OPEN DI watcr isolation \ alvc During flushing, ACTUATE the ejector isolation valve 5 to 10 timcs

7 0 ISOLATE DI water and elector valw

8 0 REMOVE clcctor isolation valve from system NDE COMPLETE a leak check ofthc ejector isolation vahc to 1 x 10 ‘ cm’/s He PLACE leak check report in Appendix 1 and SUMMARIZE results

NDE Date

1- Test Engineer Date

8.2.6 Hood Ventilation Test

Thc process vcntilation hood air flow measurements shall be conducted using a scale mock-up This test is to establish that no eddy currents arc produced while an operator is in front of the hood causing possible contamination to be spread in the operator breathing space This test shall be conducted by a qualified vent and balance group using a manikin(s) and smoke tests to establish the air flow patterns The apparatus %ill have to be set-up to supply the current design specified hood flow rate and hood face obstructions

8.2.6.1 Prerequisites

1 0 ASSEMBLE/FABRICATE test apparatus per test engineer’s direction ADJUST dampers until design flow of 1300 scfm is achieved

Apparatus fabrication I Test Engineer Date

2 0 SCHEDULE Vent and Balance to pcrform an open faced hood ventilation test with two to three people standing in front of the open faced hood

3 0

4 0

SCHEDULE Industrial Safety to provide noise level determination

Video tape smoke test

8.2.6.2 Instructions for Ventilation and Noise Test

1 0

2 0

Vent and Balance ESTABLISH hood capture velocity of 125 FPM

PLACE personnel or manikins (3) in the expected working space in front of the hood NOTE personnel locations on location map providcd in Log Book

3 0 Smokc TEST pursuant to Vent and Balance procedure (to be provided by V & B) and video tape rcsults

21

HNF-2402 Rcv 0

4 0

5 0

h 0

ADJUST f l o ~ as necessary to maintain particulate capture and minimiic personnel exposurc

RECORD final flow ralc scltings and capture velocities in Log Book

Industrial Safcty ESTABLISH noise level readings at working distance and DETERMINE safe distanccs for pcrsonnel without hearing protection RECORD preliminary findings in Log Book

8.2.7 Seal Ring Performance Testing

8.2.7.1 Prerequisites

1 0 INSTALL MCO in the cask

2 0

3 0

8.2.7.2 Instructions

INSTALL scal ring on cask and tighlcn bolls lo 25-30 ft Ibs

INFLATE inflalablc 0-Rings in the seal ring to 25 lo 35 psig and RECORD setting

1 0 PRESSURIZE the cask to 25 psig (+lpsig) as necessary NOTE: The MCO will float upwards approximatch lin inside the cask until contact is established with the seal ring

NDE DETERMINE leak rates through the MCO inflatable 0 - k n g , 0-Rmg scal plate bottom 0- ring, and the 0-Ring seal plate bore seal O-ring Use drawings H-1-83264 sht 1-2 and H-1-83275 shl 1-3 of Process Hood Seal Ring and Piping Assembly W-441-P4 Rcv N Procurement Spccification as necessaw for reference

M(’0 inflalablc 0-Ring leak ratc

0-King scal plalc bottom O-ring leak ratc

0 - h n g seal plate bore seal O-ring leak rate

PLACE leak test report in Appendix I

2 0

std ccisec He

std ccisec He

sld ccisec He

Seal Ring Leak rate establishment I NDE Date

/ Test Engineer Dale

8.2.8 First Article Testing Apparatus

In Lonjunclion ulsection 8 1 3 the VPSiTWS processing skid has been delivercd and installed in thc 30hE Facilit) First Article Test Bcd

Test Director Date

22

HNF-2402 Rev 0

8.2.9 MCS Computer Control Setup and Testing

A substantial amount of timc and effort is planned to setup and test the control system Since all programming has hccn donc without physical connections to the process equipment, many required program changes arc expected The MCS used in first article testing will be “first generation” and will providc thc minimum capability rcquired to pcrform the planned testing

As part of thc first article testing of the MCS, the hardware will be verified during the Construction Acccptancc Tcst # RDCIDESH MCB-SLB-A062X5-CAT-000 MC5 Hardware Con\tructron Acceptance Tect in the 30hE Building facilit\ The CAT tests will provide loop calibrations, data logging, data storagc, and dcmonstratc data transfer utiliiing lntellution softwarc The actual MCS programmed sequences and automatic lunctions \\ill bc tested as part of the 306E Test Procedures Included in these tests will hc thc drain sequencc and as much of the proposed ~acuum drving steps as available at the start of testing Othcr steps or sequences will be added as soon as they arc defined, those added during the 306E testing will he tested at that timc Since lhc rccirculalion mode is under consideration for elimination no automatic scqucnccs \\ill he programmed at this timc, howcvcr manual control will be provided A small subset of the total alarms wi l l be programcd, basically only those necessarq to support continued testing at the 306E facilit\ without thc iiccd for continuous staffing Intcrlocks [or the TWS heater will bc provided at a minimum Othcr alarms and off-normal automatic rcsponscs arc not available at this time and will be programmcd as thc) bccome ataildblc

MCS Construction Acccptancc Tcst and mockup systcms opcrational testing complete

I Control Systems Engineer Date

Test Director Datc

9.0 FIRST ARTICLE TESTING

Thc tollowing tests idcntih specific operating temperatures, prcssures, flows, bulk water amounts, howeber the parameters may changc or bc changcd during the testing phase These changes will bc documented in thc tcst log

Thc tcst apparatus for prototype or first article testing consists of a full s i ~ c prototypic MCO (which for thc purpose of this section, will be referred to as the MCO) and transportation cask (with mockup hoodseal ring and lo \m port connector assembly) connected to the first article VPS and TWS Also conncctcd to the first article VPSITWS are prototypes of the PWC, the SCHc system, an cquivalent process chiller svstcm. all shall he controlled and operated utiliiing a first generation MCS The MCO and ‘systems’ shall be connected with prototyyc proccss conncclors and equivalent lcngth piping The MCO will require instrumentation feed throughs (hcrmctic) to dctcrminc test articlc tcmpcraturcs

A sct of prcliminary and first articlc proof of pcrformancc CVD tests arc summarized in Appendix A Details of thc preliminq and first articlc tests arc provided in this section These tests are intcnded to protidc thc necessan data to aid i n systcm operation, to optimize 1 & C control and sortware process functions, and to dcmonstratc safc systcm operation during normal operation and some accident. upsct and faulted conditions These tests may bc remoxed or other tests may be substituted from thc testing program pcr thc changc control prcvioush idcntified in section 5 3 2

Thc gcncral 5cnice proccss instrumcntalion and control system performance will he tested and cditcd

23

HNF-2402 Rev 0

mainly during thc prcliminan tcst sequcncc Any control system changes that arc obscrved during testing shall be documented on a Request for Information (RFI) and in the test log hook and transmitted to thc 1 & C vendor for software implementation and the changes shall he reinstalled during a test reconfiguration or shut down intcngal, unless the changes arc ncccssary for test completion and will not violate tcst data integriti The general scrvicc I & C testing will he requircd to cxamine a small percentage of thc normal, accident. upset and faulted modc responses and fail safe positions of accident sccnarios These scenarios include line breakage and oxygcn ingress, loss of instrument air, and loss of elcctrical power at different times during the process sequence

Thc saCctq class 1 & C (SClC) performance will not be tested as part of the first article testing Jumpers will be installcd to allow the general scrvicc I & C to operatc normally and act as the SClC The safcty class helium injcction system will he tested under a small perccntagc of thc normal, accident, upset, and faultcd mode responses and fail safe positions of different accident scenarios These scenarios include linc hrcakagc and oxvgen ingress. loss of instrument air, and loss of electrical power at different times during the proccss

VPSiTWS skid, proccss hood, PWC, MCO and MCS are ready for processing

Hold Point I Test DirectoriEngineer Date

I Control Systcms Date

9.1 PRIMARY MANUAL SEQUENCES OF OPERATION

Thc following CVD first articlc tcsts can oftcn he described in terms of permutations oCMCO fuel mockup conditions and a particular type of tcst cyclc Each of these cycles may use differcnt hardware cornponcnts (vacuum pump, condenser, ctc ) opcratcd at differcnt test paramcters (temperature, flow rate. etc )

Special Prerequisites

When using computer manual sequencing, as described in this section, the valves that are refcrcnced arc to bc actuatcd in the order in which they are listed Any changes to this order, a test exccption or red liuc changc shall bc rcquircd and noted in the testing log

Main Line Break Valves MLB-V-PO01 to PO04 shall REMAIN CLOSED throughout the procedure unless otherwise statcd in thc procedure

9.1.1 Bulk Water Drain Sequence

9.1.1.1 Prerequisites

1 0 OPEN GOV 4045 GOV 4046,and PWC-S-POOI

2 0 Pump PWC-P-4035 is ON

3 0 INSURE MINIMUM walcr lcvcl in thc PWC tank AND RECORD watcr lcvcl

24

HNF-2402 Rcv 0

9.1.1.2 Special Requirements

1 0 OBSERVE FI 4050 and PI 4034 lor initial breakthrough (indicatcs draining finished) of water lebel The pressure is expected to rise quickly from vacuum to atmospheric pressurc The flow is expected to rise slightly just as the gas breaks through the system

9.1.1.3 Instructions

1 0

2 0

3 0

4 0

5 0

6 0

9.1.2

I 0

2 0

3 0

5 0

6 0

7 0

CLOSE valvcs GOV 2221,2222.1206, 1217,2204,2205,2207, PWC-R-P001, CV-BPV-POOI, CV-BPV-POO1. IXM-IV-P001 and IXM-IV-PO02

OPEN valxcs GOV 2203. 1209. 1212, 1230. 1201,and IXM-BPV-PO01

PRESSURIZE MCO through HEPA filter port to 4 PSIG (PI 1236)

OBSERVE for MCO hrcakthrough as indicatcd in 9 1 1 2 HOLD gas flow lor approximatclq 5 minuks

RECORD final PWC tank lcvcl

CONTINUE with scction 9 1 2 as directed by the test engineer

Bulk Water DI Rinse (PWC Line Flush)

DRAIN thc PWC tank to MINIMUM level AND RECORD level

PRESSURIZE MCO to 4 PSIG

OPEN GOV 2203,2204. 1212, 1230, 1209, 1201, 1202, 1217, and MOV 121 1 goes to DI watcr sidc

CLOSE GOV 2228

FLUSH PWC lines for 15 minutcs

CLOSE GOV 1201. 1230. 1209, 1212, 1204, 2203. 1202, 1217, and MOV 121 I

9.1.3 Tempered Water Heatup

1 0 CLOSE GOV 1215

2 0 OPENGOV3214, 1214

3 0

4 0

START pump TW-P-32 14

SET heatcr 7 W-HTR-32 I 1 at 50 "C

25

9.1.4

1 0

2 0

3 0

9.1.5

HNF-2402 Re\ 0

Helium Purge or Repressurize Cycle (Diptube Inlet)

SET flou controller FIC 12 I9 at I 6 or 10 scfin (purge flow or quick rcpressurization respectively)

OPEN ~ a l ~ c s GOV 1202 1209 2203,2204. and 1206

CLOSE bahcs GOV 1217, 1212, 1230, 2221, 2222,2207, and 2205

Vacuum Drying with Condenser

9.1.5.1 Prerequisite

1 0

2 (1

1 0

4 0

5 0

6 0

Vacuum Pump VPS-P-2211 is ON with helium purge

TWS 1s opcratiug and maintannng set point (typically 5 0 "C)

Bulk mater has been DRAINED (scclion 9 1 I ) from MCO (as directed by thc tcst director)

VP5 CHW operating at specdied flow and tcmperature (typically 4 gpm and TT 2236 indicatcs 2 "C)

Condenser tank (VPS-TK-2216) has been DRAINED (section 9 1 12)

SET FIC 12 I9 at 1 6 d i n and OPEN GOV 1206,1202,1209,2222,2221, and 2204

9.1.5.2 Instructions

I 0

2 0

1 0

OPEN GOV 1209,2207 2221, and 2222

CLOSE GOV 1217. 1210.2204,2203, and 2205

IF the tempcrature diffcrcncc (AT) between TI 2235 and TI 2236 is < 2 "C, CLOSE GOV 2222, 222 1 and OPEN 2203 to isolate the condenser (VPS-COND-22 13)

REDUCE FIC 1219 to 0 scfm and CLOSE valve GOV 1206

CONTINUE with vacuum pump only drying until PI 1208 IS LESS THAN 0 1 torr

4 0

5 0

9.1.6 Vacuum Drying without Condenser

9.1.6.1 Prerequisites

I 0

2 0

3 0

4 0

Vacuum pump VPS-P-2211 is ON mith helium purge

TWS is operating and maintaining sct point (typically 50 "C)

Bulk water has been DRAINED (section 9 1 I) from MCO (as directed by the test director)

SET FIC 12 I 9 at I 6 scfm and OPEN GOV 1206, 1202, 1209,2222,2221, and 2204

26

HN F - 2 4 0 2 Rev 0

9.1.6.2 Instructions

1 0 OPEN GOV 1209,2207, and 2203

2 0 CLOSE GOV2222.2221. 1217. 1230, and2204

9.1.7

Full 8-4-4 Cyclc

Normal Vacuum Drying Cycle (8-4-4 Sequencing)

Vacuum pump operated for X hours with condenser and helium purge (at I 6 scfm), followed bq a 4 hour helium rccycle or purge (at I O scfm then I 6 scfm), followed by 4 hours of vacuum pump onh operation with helium purge (at 1 6 scfm) Thc 4 hour cycles arc rcpcated until the MCO is "dry"

9.1.7.1 Prerequisites

1 0

2 0

1 0

4 0

5 0

6 0

Vacuum Pump VPS-P-2211 is ON with helium purgc

TWS is operating and maintaining sct point (lqpically 5 0 "C)

Bulk uatcr has bccn DRAINED (section 9 I I ) from MCO (as directed by thc test director)

VPS CHW opcrating at spccificd f l o ~ and tempcralure (tqpically 4 gpm and TT 2236 indicates 2 "C)

Condcnser tank (VPS-TK-2216) has been DRAINED (section 9 1 12)

SET FIC 12 I9 at I 6 scfm and OPEN GOV 1206, 1202. 1209,2222,2221, and 2204

9.1.7.2 Vacuum Drying with Condenser (8 hour cycle)

CondcnscriPurge Only Vacuum Pump and Condenser Operatlon (1 "C ) with Helium Purge at Cycle I 6 scfm for 8 hours

1 0

2 0

3 0

4 0

5 0

6 0

7 0

SET FIC 1219 to 4 scfm

OPEN GOV 1209 and 2207

CLOSE GOV 1217, 1230,2204,2203, and 2205

CONTINUE 4 scfm hclium flow for 10 minutes to reduce steam flow through the MCO internal HEPA filters

REDUCE hclium flon ADJUST FIC 12 19 to 1 6 scfm

IF time is 4 hours uudcr vacuum AND AT between TI 2235 and TI 2236 is LESS THAN 2 "C THEN OPEN 2203 AND CLOSE GOV 2222, 2221, 1202, and 1206 to bypass and isolate thc condcnser (VPS-COND-2213) and stop the helium purge

IF pressure in MCO is GREATER THAN 9 torr AFTER 5 minutes from the condenscr bypass, OPEN GOV 1206 and 1202 to rcsume vacuum drying with purge but without condenser UNTIL thc

27

HNF-2402 Rev. 0

8 0

9 0

IO 0

I 1 0

12 0

timc under \ acuum is 7 5 hours

IF time under ~acuum EQUALS 7 5 hours THEN GOTO section 9 1 7 3

NO1 E: Stcp 8 0 applies to all steps in this scction

IF thc tcmpcraturc differcnce (AT) between TI 2235 and TI 2236 is GREATER THAN 2 "C AND time under \ acuum is LESS THAN 7 5 hours THEN CONTINUE the evacuation

IF time is LESS THAN 7 5 hours under vacuum AND AT between TI 2235 and TI 2216 is LESS THAN 2 'C THEN OPEN 2203 AND CLOSE GOV 2222, 2221,1202, and 1206 lo bypass and isolate the condenser (VPS-COND-2213) and stop the hchum purge

IF pressurc in MCO is GREATER THAN 9 torr AFTER 5 minutcs from the condenser bypass OPEN GOV I206 and 1202 to rcsumc vacuum drying with purge but without condenser UNTIL the time under \ acuum is 7 5 hours

IF pressurc (PT 1208) dccrcases in pressure and can be maintained BELOW 0 1 torr for 15 minutes, GOTO section 9 1 7 5, OTHERWISE OPEN GOV 1206 and 1202 to resume vacuum drying with purgc but vithout condenser UNTIL thc timc under vacuum is 7 5 hours

9.1.7.3 Helium Recycle (Purge Cycle- 4 hours) Only a helium rccycle or purgc at 10 scfm then reduced to 1 6 scfm is pcrformed to dry the MCO for 4 hours

I 0 CL.OSE GOV 2207

2 0

3 0

4 0

5 0

6 0

SET FIC 1219 at 10 scfnm

OPEN GOV 1209,2221 2222, and 2204 to valw in thc condenser

CLOSE GOV 1217. 1230.2203,2205. and 1212

AFTER 5 minutcs of 10 scfm purge flow REDUCE FIC 12 I9 to I 6 scfm

AFTER 3 hours 55 minutcs of purging, GOTO 9 I 7 4

9.1.7.4 Vacuum Drying without Condenser (4 hour cycle)

CondcnseriPurge Only Vacuum Pump and Condcnser Operation ( I "C ) with Helium Purgc at Cyclc 1 6 scfm for 4 hours

I 0

2 0

3 0

4 0

INCREASE FIC 1219 to 4 scfm

OPEN GOV 1209.2204, and 2203

CLOSE GOV 1217, 1230 ,2203,2205.2207,2221, and2222

AFTER 30 minutes o f 4 scfm flow. CLOSE GOV 2204, OPEN 2207. AND REDUCE flow to 1 6 scfin for 15 minutcs

28

HNF-2402 Rev 0

5 0

6 0

7 0

x 0

CLOSE GOV 1202 and 1206 to stop helium flow

I F time undcr vacuum EQUALS 3 5 hours THEN GOTO section 9 1 7 3

NOTE: Step 6 0 applies to all steps in this scclion

IF pressure in MCO is GREATER THAN 0 torr AFTER 5 minutes from the condenser bypass, OPEN GOV 1206 and 1202 to resume vacuum drying with purge but without condenser UNTIL the time under 1 acuum is 3 5 hours THEN REPEAT section 9 I 7 3

IF pressurc (PT I20X) decreases in prcssurc and can be maintained BELOW 0 I torr for 15 minutes, GOTO section 9 I 7 5, OTHERWISE OPEN GOV 1206 and 1202 to resume vacuum drying with purge but nithout condenser UNTIL the time under vacuum is 3 5 hours THEN REPEAT section 0 I 7 3

9.1.7.5 Pressure Rebound Test

NOTE: IF time under vacuum (7 5 hrs or 3 5 hrs section 9 1 7 2 or 9 1 7 4 respectively) is exceeded at am time during these following steps GOTO 9 1 7 3

1 0

2 0

3 0

4 0

S O

6 0

7 0

ISOLATE MCO CLOSE GOV 1230. 1202. 1206, and 1209

MONITOR PRESSURE over 10 MINUTES

IF pressure RISE is GREATER THAN 0.5 TORR in 10 minutes, RESUME vacuum drying with purge but without condenser OPEN GOV 1209, 1202, 1206 AND INCREASE purge to 1 6 scfm to continuc vacuum drying without condenser UNTIL the time under vacuum is exceeded (7 5 hrs or 3 5 hrs section 9 I 7 2 or 9 I 7 4 respectively)

NOTE IF returning to section 9 1 7 4, REPEAT steps 1 0 through 3 0 of this section EVERY HOUR UNTIL the step 3 0 CANNOT be met, THEN CONTINUE with step 4 0

ISOLATE MCO CLOSE GOV 1230, 1202, 1206. and 1209

MONITOR PRESSURE over 1 HOUR

IF pressure RISE is GREATER THAN 3 TORR in lhour, RESUME vacuum drying with purge but nithout Londenser OPEN GOV 1209, 1202, 1206 AND INCREASE purgc to I 6 scfm to continue \ acuum drying without condenser UNTIL the time under vacuum is exceeded (7 5 hrs or 3 5 hrs section 0 I 7 2 or 9 I 7 4 respectwely)

IF pressure RISE IS LESS THAN 3 TORR in I hour, the MCO is DRY AND thc test IS COMPLETE CONTACT test director or test engineer

29

HNF-2402 Rev 0

9.1.8 Proof Drying Mode

9.1.8.1 Prerequisites

I 0

2 0

MCO is LESS THAN 9 torr AND is DRY

TWS is opcrating at 50°C (Hot standby modc)

9.1.8.2 Instructions

1 0

2 0

3 0

4 0

5 0

6 0

7 0

RETURN to vacuum purgc without condenser mode and without purge CLOSE GOV 1202 1230, 12 17,2221 and 2222 AND OPEN GOV 1209,2203, and 2207

MAINTAIN \. acuum IC\ CIS bclow < 9 torr for 19 hours (should be less than 0 5 torr)

IF prcssurc RISES abocc 9 torr within 2 hours. a systcm leak has occur and repair is rcquired CONTACT test director

AFTER 19 hours, ISOLATE MCO CLOSE GOV 1209

CONFIRM prcssure RISE is LESS THAN 3 TORR in 1 hour The MCO IS DRY AND the test is COMPLETE

RLPRESSURIZE thc MCO to 1-5 psig SET FIC 1219 to 0 5 scfm AND OPEN GOV 1206 and I202

MONITOR PT 1236 until 1-5 psig is met THEN CLOSE GOV 1206 and 1202

9.1.9 MCO Cooling

9.1.9.1 Prerequisites

1 0

2 0

MCO is at 5 0 ' ~ or at discrction of the test cngineer and notcd in the logbook

MCO is lillcd with Hclium at 1-5 psig

9.1.9.2 Instructions

1 0

2 0

3 0

SET thc Tcmpcred Water Heatcr controls (TIC 3205) to 25 "cor at the discrction of thc test enginccr AND OPEN GOV 3201 for TW cooling flow UNTIL Ihc TT 3212 and the MCO shell TCs (TI; 6- 10) rcach LESS THAN 25 "cor at thc discretion of thc test engineer (NOT to be below 1Oc and notcd in the test logbook )

Whcn temperature is achicvcd, increase MCO pressurc to 7 3+1 5pSig SET FIC 1219 to 0 5 scfm AND OPEN GOV 1206 and 1202

MONITOR PT 1236 until 7 3 i 1 5psig is met THEN CLOSE GOV 1206, 1202, and 3201

30

HNF-2402 Rev 0

9.1.10 MCO Water Fill

First article tcsting requires the MCO to be filled to ccrtain levels or certain volumes orwater without removing the MCO shield plug The following stcps will dictate how this process can he done safely without damage to the cquipmcnt or submerging the MCO internal filters

9.1.10.1 Computer Manual Water Fill for Large Quantities of Water

9.1.10.2 Prerequisites

1 0

2 0

SHUT OFF pump PWC-P-4035

CLOSE GOV 4046 and 4045

9.1.10.3 Instructions

1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

i o 0

I 1 0

12 0

13 0

FILL thc EMPTY WRT with the specified amount of water PLUS 20 gallons to offset the WRT dip Icg measurement

START the \ acuum dlying with condenser manual opcration as referred to in section 9 1 5

ALLOW thc sjstcm pump to -100 Torr

ISOLATE the MCO b j CLOSING GOV 1209

Manually OPEN thc check valve bypass vahe in the PWCiHood spool piccc

ISOLATE thc IXM and place into IXM bypass by CLOSING IXM-IV-POOI and PO02 and OPENING IXM-BPV-PO0 I

OPEN GOV 1230 This allows watcr begin floming into the MCO

OBSERVE the WRT until the WRT indicates approximate the watcr quantity or the WRT level IS bclow thc WRT dip leg

RECORD thc amount of watcr in the PWCiMCO system in the test log book

CLOSE thc IXM bypass ialvc IXM-BPV-POOI

WAIT approximatclq 5 minutes

CLOSE GOV 1230

VENT MCO per scction 0 1 I I

9.1.10.2 Manual Water Fill for Small Volumes of Water

1 0 OPEN the MCO boroscopc inspection port

31

HNF-2402 Rev 0

2 0

3 0

4 0

FILL with dcsired amount of watcr utili/ing a funnel

RECORD thc amount of nater in the MCO in the appropriate test log book

CLOSE the MCO boroscope inspection port

9.1.11 MCO Venting

9.1 .I 1 .I Prerequisites

I 0 CLOSE GOV 2207 to Isolate vacuum pump VPS-P-221 I

9.1.11.2

I 0

2 0

3 0

4 0

Manual MCO Only Venting Instructions

Computer manual CLOSE GOV 1230 1202. and 1209

OPEN MCO boroscopc port

ALLOW MCO vent UNTIL MCO pressure IS at atmospherc

CLOSE MCO boroscopc port

9.1.11.3

1 0

2 0

3 0 CLOSE MCO MLB-V-PO01

Note: For svstem on$ venting. ~t'necessarq, without venting MCO, CLOSE both MCO port valves using the process connectors

Manual System and MCO Venting

OPEN main line break lalve MLB-V-PO01

ALLOW MCO vent UNTIL MCO pressure IS at atmospherc

9.1.12 Condenser Tank Drain Instructions

9.1.12.1 Prerequisites

1 0

2 0

3 0

OPEN GOV 4045 and GOV 4046

Pump PWC-P-4035 is ON

INSURE MINIMUM water lcvcl in the PWC tank AND RECORD water level

9.1.12.2 Instructions

I 0 CLOSE GOV 1230, 1202, 1209,2203,2207,2205, and 2222

32

2 0

3 0

4 0

9.2

HNF-2402 Re1 0

OPEN 2204 2221 1212 and 2216 to helium purge and drain condenser tank (VPS-TK-2216)

CONTINUE condenser tank drain UNTIL break through occurs as indicated bv PI 4034

CLOSE GOV 1212 2221 2204. and 2216

BASELINE ESTABLlSHMENT

This testing or the drv MCO shall establish initial system vacuum baselines and overall system operational \erification for determining VPWMCO svstem cbacuation times for thermal model verification (I e Process Simulator). MCO baseline dnmess for pressure and moisture sensors, VPS/MCO system leakage, and slstcm OK-gassing for the RGA baselines operation or the Helium purge and recirculation systems, tempered water syetem, the PWC eductor (sectio